TROUBLE SHOOTING ARC WELDING EQUIPMENT

Problem: Welder will not start (Starter not operating)

Cause: Power circuit dead.
Remedy: Check voltage.
Cause: Broken power lead.
Remedy: Repair.
Cause: Wrong supply voltage.
Remedy: Check nameplate against supply.
Cause: Open power switches
Remedy: Close.
Cause: Blown fuses.
Remedy: Replace.
Cause: Overload relay tripped.
Remedy: Let set cool. Remove cause of overloading.
Cause: Open circuit to starter button.
Remedy: Repair.
Cause: Defective operating coil.
Remedy: Replace.
Cause: Mechanical obstruction in contactor.
Remedy: Remove.
Problem: Welder will not start (Starter operating)
Cause: Wrong motor connections.
Remedy: Check connection diagram.
Cause: Wrong supply voltage.
Remedy: Check nameplate against supply.
Cause: Rotor stuck.
Remedy: Try turning by hand.
Cause: Power circuit single-phased.
Remedy: Replace fuse; repair open line.
Cause: Starter single-phased.
Remedy: Check contact of starter tips.
Cause: Poor motor connection.
Remedy: Tighten.
Cause: Open circuit in windings.
Remedy: Repair.
Problem: Starter operates and blows fuse
Cause: Fuse too small.
Remedy: Should be two to three times rated motor
current.
Cause: Short circuit in motor connections.
Remedy: Check starter and motor leads for insulation
from around and from each other.
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––––––––– TROUBLE SHOOTING ARC WELDING EQUIPMENT
Problem: Welder runs but soon stops
Cause: Wrong relay heaters
Remedy: Renewal part recommendations
Cause: Welder overloaded
Remedy: Considerable overlaod can be carried only for
a short time
Cause: Duty cycle too high
Remedy: Do not operate continually at overload currents
Cause: Leads too long or too narrow in cross section
Remedy: Should be large enough to carry welding current
without excessive voltage drop
Cause: Power circuit single-phased
Remedy: Check for one dead fuse or line
Cause: Ambient temperature too high
Remedy: Operate at reduced loads where temperature
exceeds 100° F
Cause: Ventilation blocked
Remedy: Check air inlet and exhaust openings
Problem: Welding arc is loud and spatters excessively
Cause: Current setting too high
Remedy: Check setting and output with ammeter
Cause: Polarity wrong
Remedy: Check polarity, try reversing, or an electrode of
opposite polarity
Problem: Welding arc sluggish
Cause: Current too low
Remedy: Check output, and current recommended for
electrode being used
Cause: Poor connections
Remedy: Check all electrode-holder, cable and ground-
cable connections. Strap iron is poor
ground return
Cause: Cable long or too small
Remedy: Check cable voltage drop and change cable
Problem: Touching set gives shock
Cause: Frame not grounded
Remedy: Ground solidly
Problem: Generator control fails to vary current
Cause: Any part of field circuit may be short circuited
or open circuited
Remedy: Find faulty contact and repair
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TROUBLE SHOOTING ARC WELDING EQUIPMENT –––––––––
Problem: Welder starts but will not deliver welding current
Cause: Wrong direction of rotation
Remedy: See INITIAL STARTING
Cause: Brushes worn or missing
Remedy: Check that all brushes bear on commutator with
sufficient tension
Cause: Brush connections loose
Remedy: Tighten
Cause: Open field circuit
Remedy: Check connection to rheostat, resistor, and
auxiliary brush studs
Cause: Series field and armature circuit open
Remedy: Check with test lamp or bell ringer
Cause: Wrong driving speed
Remedy: Check name plate against speed of motor or
belt drive
Cause: Dirt, grounding field coils
Remedy: Clean and reinsulate
Cause: Welding terminal shorted
Remedy: Electrode holder or cable grounded
Problem: Welder generating but current falls off when welding
Cause: Electrode or ground connection loose
Remedy: Clean and tighten all connections
Cause: Poor ground
Remedy: Check ground-return circuit
Cause: Brushes worn worn off
Remedy: Replace with recommended grade. Sand to fit.
Blow out carbon dust.
Cause: Weak brush spring pressure.
Remedy: Replace or readjust brush springs
Cause: Brush not properly fitted
Remedy: Sand brushes to fit
Cause: Brushes in backwards
Remedy: Reverse
Cause: Wrong brushes used
Remedy: Renewal part recommendations
Cause: Brush pigtails damaged
Remedy: Replace brushes
Cause: Rough or dirty commutator
Remedy: Turn down or clean commutator
Cause: Motor connection single-phased
Remedy: Check all connections
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